Method and apparatus for separation of milk, colostrum, and whey

ABSTRACT

Apparatus and method for separation of milk and milk products, e.g., involving sequential separation of milk, clostrum, and whey components by cross-flow filtration. The apparatus and method in a preferred aspect employ cross-flow filtration, chromatography and fermentation to separate and fully utilize the components of milk, clostrum, and whey to generate numerous individual components, minimize waste, lower adverse environmental issues and provide enhanced economic benefits to dairy producers. A wide variety of consumer and nutraceutical products can be produced from the fractions and/or sub-fractions of milk products obtained from such separation. The invention further contemplates a methodology for selecting optimum membrane, device, and operating conditions to achieve a desired separation.

FIELD OF THE INVENTIOIN

[0001] The present invention relates to method and apparatus forsequential separation of various nutritional components of milk,particularly sequential separation of various milk proteins,carbohydrates, enzymes, and minerals contained in milk, colostrum, whey,or other diary products, using cross-flow filtration modules.

BRIEF DESCRIPTION OF THE RELATED ART

[0002] Milk contains various useful and beneficial components.Butterfat, casein, and lactose are the most commonly known dairycomponents. Some other components, which are equally important althoughless known, include lactoferrin, lactoperoxidase, immunoglobulins,sialyllactose, phospholipids, α-lactalbumin, and β-lactoglobulin.

[0003] Cheese manufacturing processes involve separation of casein, aninsoluble protein contained in whole milk, from other components of milkby precipitation. The two predominant precipitation techniques arerennet precipitation and acid precipitation, which are alternativelyutilized, depending on the specific type of cheese to be produced.

[0004] The supernatant fluid generated during cheese manufacturingprocess is commonly referred to as whey. Proteins contained in whey,which are soluble proteins including lactoferrin, lactoperoxidase,immunoglobulins, albumin, α-lactalbumin, and β-lactoglobulin, arehistorically referred to as whey proteins. In the present application,the terms “whey proteins” and “milk proteins” are synonymous with oneanother, and are used interchangeably to refer to those soluble proteinscontained in milk, in contrast to the insoluble components such ascasein.

[0005] Whey, a byproduct of the cheese manufacturing process, has longbeen the predominant source of milk proteins, and significant effortshave been devoted to separation and isolation of various whey proteins.Despite the intensive efforts that have been focused on achieving thisobjective, the separation and isolation of various whey proteins, suchas the aforementioned lactoferrin, lactoperoxidase, immunoglobulins,albumin, α-lactalbumin, and β-lactoglobulin, still heavily depend on useof conventional chromatography and precipitation methods.

[0006] The chromatography separation method is expensive and complex,requiring continual replacement of the chromatographic resin, as well asadjustments of pH value and ion concentration of the whey prior to thechromatography separation process.

[0007] Moreover, chromatography separation is suitable only forpost-casein-precipitation protein extraction, because it necessarilyrequires whey instead of whole milk as the starting material.

[0008] Further, the conventional chromatographic separation methodundesirably changes the natural quality and character of milk, by addingchemical additives thereto, in order to effect separation and to enhanceproduct yield.

[0009] In one approach to chromatographic separation of milk, Mozaffaret al. U.S. Pat. No. 6,096,870, entitled “Sequential Separation of Whey”and issued Aug. 1, 2000, discloses a milk chromatographic purificationmethod, comprising the following thirteen steps:

[0010] 1) adding rennet to precipitate casein;

[0011] 2) clarifying the whey using a clarifier;

[0012] 3) centrifuging the whey to remove fat components;

[0013] 4) adjusting pH value of the whey to 3.8 by addition of aceticacid;

[0014] 5) loading the whey on an anion exchange chromatographic column;

[0015] 6) column washing using 0.05M sodium acetate;

[0016] 7) elution with 0.1 M sodium acetate and 0.5 M sodium chloride toseparate immunoglobulin and β-lactoglobulin;

[0017] 8) column reconditioning with 0.05 sodium acetate;

[0018] 9) eluting for the second time with 0.1 M sodium acetate and 0.1M sodium chloride to separate α-lactalbumin;

[0019] 10) column reconditioning for the second time with 0.05M sodiumacetate;

[0020] 11) eluting for the third time with 0.05M sodium phosphate toseparate bovine serum albumin;

[0021] 12) eluting for the fourth time with 0.05 M sodium phosphate and0.5 M sodium chloride to separate lactoferrin; and

[0022] 13) cleaning the chromatographic column with sodium hydroxide,sodium chloride, and alcohol.

[0023] Clearly, such chromatography separation process, by adding one ormore precipitants, i.e., rennet or acid, and one or more other solutionssuch as sodium acetate, sodium chloride, and sodium phosphate into thewhey, substantially and undesirably alters the natural quality andcharacter of milk. Moreover, the chromatography process incursadditional expenses relating to necessary downstream removal of thoseunnatural additives from the separated whey proteins, which otherwiseconstitute contaminants that compromise the nutritional andcompositional integrity of the natural milk products.

[0024] Similarly, conventional precipitation method for purifying wheyproteins also requires adjustment of pH value and temperature, andaddition of various chemicals and salts that are not natural componentsof milk. For example, selective precipitation of β-lactoglobulin fromwhey requires adjustment of the pH value of whey to 4.65, whichundesirably alters the natural quality of whey.

[0025] See Amundson, C. H., Watanawanichakorn, S., and Hill, C. G.,Production of Enriched Protein Fractions of Beta-Lactoglobulin andAlpha-Lactalbumin from Cheese Whey, Journal of Food Processing andPreservation, vol. 6, pp. 55-71 (1982).

[0026] It is therefore an object of the present invention tosequentially separate various milk components, without introducingunnatural additives.

[0027] It is another object of the present invention to provide anintegral separation system for sequential separation and isolation ofbeneficial milk proteins, with significantly improved efficiency andreduced costs, suitable for commercial scale-up and mass production ofpurified milk proteins.

[0028] It is yet anther object of the present invention to separate themilk proteins without first precipitating casein.

[0029] Other objects and advantages of the invention will be more fullyapparent from the ensuing disclosure and appended claims.

SUMMARY OF THE INVENTION

[0030] The invention relates in one broad aspect to a method andapparatus for separating raw milk, milk-based diary product, or dairywaste into multiple components in a sequential fashion, using cross-flowfiltration modules, as described more fully hereinafter.

[0031] In one specific aspect, the present invention relates to a methodfor separating milk by cross-flow filtration, comprising the steps of:

[0032] a) providing a milk source;

[0033] b) effectuating flow of milk from the milk source through one ormore cross-flow filtration modules, using a fluid delivery means,wherein each fluid delivery means is connected to at least onecross-flow filtration module; and

[0034] c) sequentially capturing one or more filtration fractionsgenerated by the cross-flow filtration modules.

[0035] The term “milk” in the present application means any type ofnatural or modified dairy products, including, but not limited to: milk,whole milk, skim milk, milk fat, colostrum, whey, milk concentrates,milk dilutes, milk subcomponents, milk isolates, and other lacticoutputs from bovine, human, goat, rabbit, deer, or other mammals, aswell as mixtures of two or more of the foregoing.

[0036] In another specific aspect, the present invention relates to anapparatus for isolating and purifying one or more milk components,comprising:

[0037] a) a milk source;

[0038] b) one or more cross-flow filtration modules communicativelyconnected to the milk source, for generating one or more filtrationfractions;

[0039] c) one or more fluid delivery means connected to each of thecross-flow filtration modules for creating sufficient flow of milkthrough the cross-flow filtration modules to effect separation of milkcomponents; and

[0040] d) one or more means downstream of each of the cross-flowfiltration modules for sequentially capturing one or more fractionsgenerated by the cross-flow filtration modules.

[0041] “Cross-flow filtration module” refers herein to a type of filtermodule or filter cassette that comprises a porous filter element acrossa surface of which the liquid medium to be filtered is flowed in atangential flow fashion, for permeation through the filter element ofselected component(s) of the liquid medium.

[0042] In a cross-flow filtration module employed in the presentinvention, the shear force exerted on the filter element (separationmembrane surface) by the flow of the liquid medium serves to opposeaccumulation of solids on the surface of the filter element. Usefulcross-flow filters include microfiltration, ultrafiltration,nanofiltration and reverse osmosis filter systems. The cross-flow filtermay comprise a multiplicity of filter sheets (filtration membranes) inan operative stacked arrangement, e.g., wherein filter sheets alternatewith permeate and retentate sheets, and as a liquid to be filtered flowsacross the filter sheets, impermeate (non-permeating) species, e.g.,solids or high-molecular-weight species of diameter larger than thefilter sheet's pore size(s), are retained and enter the retentate flow,and the liquid along with any permeate species diffuse through thefilter sheet and enter the permeate flow. In a preferred embodiment ofthe present invention, such cross-flow filtration module comprises apermeate collection and discharge arrangement, a feed inlet, a retentateoutlet, and multiple fluid-flow sub-channels that may for example beequidistant to the inlet and the outlet.

[0043] Cross-flow filtration modules and cross-flow filter cassettesuseful in practice of the present invention are commercially availablefrom North Carolina SRT, Inc. (Cary, N.C.), and are variously describedin the following United States patents of Henry B. Kopf: U.S. Pat. No.4,867,876, “Filter Plate, Filter Plate Element, and Filter ComprisingSame, issued Sep. 19, 1989; U.S. Pat. No. 4,882,050, same title, issuedNov. 21, 1989; U.S. Pat. No. 5,034,124, same title, issued Sep. 11,1990; U.S. Pat. No. 5,049,268, same title, issued Sep. 17, 1991; U.S.Pat. No. 5,232,589, “Filter Element and Support, issued Aug. 3, 1993;U.S. Pat. No. 5,342,517, “Filter Cassette Article,” issued Aug. 30,1994; U.S. Pat. No. 5,593,580, same title, issued Jan. 14, 1997; andU.S. Pat. No. 5,868,930, same title, issued Feb. 9, 1999; thedisclosures of all of which are hereby incorporated herein by referencein their respective entireties.

[0044] One specific aspect of the present invention relates toseparation of a casein-rich fraction and a casein-depleted fraction ofmilk, comprising the steps of:

[0045] a) providing a source of milk;

[0046] b) optionally flowing the milk through a cream separator toremove all or at least a portion of the fatty component of the milk;

[0047] c) optionally pasteurizing the milk, using a pasteurizer;

[0048] d) flowing the milk through a cross-flow filtration module toseparate the milk into a casein-rich retentate fraction and acasein-depleted permeate fraction; and

[0049] e) recovering both the casein rich fraction and the caseindepleted fraction generated by the cross-flow filtration module.

[0050] The casein-rich fraction generated by such process can be usedfor manufacturing various dairy products, such as cheese, milk powder,and substrate for cheese production or milk protein concentrate. Thecasein-depleted fraction generated by such process contains varioussoluble whey proteins, such as IgG, albumin, alpha- andbeta-lactoglobulin, and it can be used for manufacturing of whey proteinisolates, subcomponents, and concentrates.

[0051] During prior art cheese-making processes, whey proteins areusually harvested from the supernatant waste of cheese manufacturing andtherefore contain casein-precipitants such as rennet or acid, whichdeleteriously reduce the quality and nutritional value of the wheyproteins thus obtained.

[0052] By contrast, the method of the present invention separates caseinfrom the milk without introducing any chemical precipitants that willundermine the nutritional integrity of natural milk. Thus, thecasein-separation process according to the present invention creates twoliquid fractions, one being enriched in casein and the other beingdepleted of casein, in which both are free of chemical precipitants. Thecasein-depleted fraction is a clear yellow-green liquid containingunaltered immunoglobulins, α-lactalbumin, β-lactoglobulin, bovine serumalbumin, lactoferrin, lactoperoxidase, immunoglobulins, carbohydrates,peptides, sialyllactose and lactose, which can be subject to furtheruses.

[0053] Moreover, in the mass production of milk proteins and powdermilk, it is desirable to utilize all of the beneficial components of themilk feedstock. A preferred aspect of the present invention thereforerelates to an integral process for sequentially isolating each ofmultiple useful components of milk, thereby separating milk intomultiple fractions to facilitate efficient uses of each fraction, withminimal waste of beneficial components.

[0054] Such integral process comprises the steps of:

[0055] 1) providing a milk source;

[0056] 2) optionally removing all or at least a portion of fattycomponent of the milk supplied by the milk source, using a creamseparator;

[0057] 3) optionally pasteurizing the milk, using a pasteurizer;

[0058] 4) optionally flowing the milk through a first cross-flowfiltration module, which filters out matter that is not naturalcomponent(s) of milk, such as bacteria;

[0059] 5) flowing the (optionally filtered) milk through a secondcross-flow filtration module to separate it into a retentate casein-richfraction and a permeate casein-depleted fraction;

[0060] 6) capturing the retentate casein-rich fraction;

[0061] 7) flowing the permeate casein-depleted fraction of the milkthrough a third cross-flow filtration module suitable to form aretentate fraction that is enriched with macromolecules such as albuminand immunoglobulins and a permeate fraction depleted in suchmacromolecules;

[0062] 8) capturing the retentate fraction that is enriched withmacromolecules such as albumin and immunoglobulins;

[0063] 9) flowing the permeate fraction depleted of the macromoleculesthrough a fourth cross-flow filtration module to form aβ-lactoglobulin-rich retentate fraction and a β-lactoglobulin-depletedpermeate fraction;

[0064] 10) capturing the β-lactoglobulin-rich retentate fraction;

[0065] 11) flowing the β-lactoglobulin-depleted permeate fractionthrough a fifth cross-flow filtration module to form anα-lactalbumin-rich retentate fraction and an α-lactalbumin-depletedpermeate fraction;

[0066] 12) capturing the α-lactalbumin-rich retentate fraction;;

[0067] 13) flowing the α-lactalbumin-depleted permeate fraction througha sixth cross-flow filtration module to form a complexcarbohydrates-rich retentate fraction and a complexcarbohydrates-depleted permeate fraction;

[0068] 14) capturing the complex carbohydrates-rich retentate fraction;

[0069] 15) flowing the complex carbohydrates-depleted permeate fractionthrough a seventh cross-flow filtration module to form a lactose-richretentate fraction and a lactose-depleted permeate fraction;

[0070] 16) capturing the lactose-enriched retentate fraction;

[0071] 17) discharging the lactose-depleted permeate fraction out of thesystem.

[0072] Such integral process enables a maximal utilization of beneficialcomponents contained in milk. It also achieves the purpose of minimizingwaste, prolonging the shelf life of the milk product, and maintainingthe natural nutritional integrity of milk.

[0073] In one preferred embodiment of the present application, each ofthe cross-flow filtration modules comprises a permeate collectionstructure, an inlet, an outlet, and multiple fluid-flow sub-channelsthat may for example be equidistant (equally close) to the inlet andoutlet. The cross-flow filtration modules are preferably connected toone or more fluid delivery (feed) means, which facilitates the flow ofmilk or fraction of the milk through the cross-flow filtration module ata sufficient shear rate.

[0074] It is also preferred to provide temperaturecontrolling/monitoring means to control and monitor the temperature ofthe fluids processed by the cross-flow filtration modules. Since theflow rates of milk or fraction of milk through each cross-flowfiltration module correlate with temperatures, such temperaturecontrolling/monitoring means function so as to specifically enhance thespeed of the separation process. Moreover, the temperaturecontrolling/monitoring means can be used to control microbial growth andto increase membrane performance and separation characteristics.

[0075] One specific embodiment of the present invention provides meansfor (1) cleaning the milk-processing equipment, such as the cross-flowfiltration modules and the fluid delivery means, and (2) recycling watergenerated by both the milk-separation process as well as theequipment-cleaning process.

[0076] In another embodiment of the present application, one or morefractions generated by the integral separation process of the inventioncan be further fractioned, isolated, purified, or otherwise modified.

[0077] For example, the retentate fraction enriched with albumin andimmunoglobulins from the third cross-flow filtration module can befurther separated and purified to form albumin and immunoglobulins,using a method such as chromatography, cross-flow chromatography,cross-flow filtration, etc. It is also preferable in respective aspectsof the invention to separate and purify β-lactoglobulin andα-lactalbumin from the β-lactoglobulin and α-lactalbumin-rich fractionsgenerated by the separation process, or to separate and purify complexcarbohydrates from the complex carbohydrates-rich fraction, using themethods described hereinabove.

[0078] The lactose-rich retentate fraction from the seventh cross-flowfiltration module can also be crystallized or fermented to formadditional useful products, such as for example lactobacillus, lacticacid, and Vitamin B-12. It is also preferable in various embodiments ofthe invention to subject such lactose-rich fraction to a bacterial orenzymatic process to further improve its nutritious value.

[0079] Another aspect of the present invention relates to production ofnovel dairy products, by combining two or more milk fractions obtainedfrom the integral separation process of the present invention. Forexample, one can add the fatty component of milk isolated by the creamseparator to the casein-rich fraction generated by the second cross-flowfiltration module, and then dry it to form milk powder enriched withmilk fat. As another example, it is also desirable in variousembodiments of the invention to add α-lactalbumin to the casein-depletedfraction of the milk generated by the second cross-flow filtrationmodule, to form an α-lactalbumin-enriched soluble milk proteinconcentrate. Various other combinations of one or more milk fractionsproduced by the method of the present invention, are readilydeterminable by a person ordinarily skilled in the art.

[0080] In various specific embodiments of the invention, it is desirableto dry or otherwise condense the milk components that have beenseparated and purified by the methods described hereinabove, for ease ofpreservation, storage, and transportation. Various techniques can beemployed, including, but not limited to, lyophilization, spray-drying,freeze-drying, crystallization, and evaporation.

[0081] In further embodiments of the invention, therapeutic componentsfrom milk (for example, blood clotting Factor VIII, proteins, hormones,monoclonal antibodies) of transgenic and/or hyper-immunized mammals areproduced. Either column and/or cross-flow chromatography steps can beutilized in order to yield products of necessary purities, e.g., asethical human therapeutic compounds for direct intravenous and/orintramuscular injection.

[0082] The process of generating such an ethical human therapeuticcompound of appropriate purity in one embodiment of the inventioncomprises the steps of:

[0083] a) providing a source of milk from either a transgenic and/orhyper-immunized mammal;

[0084] b) optionally flowing the milk from the milk source through acream separator to remove all or at least a portion of the fattycomponent of such milk;

[0085] c) optionally pasteurizing the milk, using a pasteurizer;

[0086] d) optionally flowing the milk through a first cross-flowfiltration module to filter out foreign matter that is not naturalcomponent(s) of milk, such as bacteria;

[0087] e) flowing the filtered milk through a second cross-flowfiltration module to form a casein-rich retentate fraction and acasein-depleted permeate fraction;

[0088] f) capturing the casein-rich retentate fraction;

[0089] g) flowing the casein-depleted permeate fraction through achromatographic resin that is capable of binding at least one targetcomponent of the milk; and

[0090] h) concentrating and/or diafiltering the eluting target componentusing a cross-flow chromatographic process.

[0091] The term “target component” as used herein is defined as a humantherapeutic agent, e.g., a compound such as a monoclonal antibody,immunoglobulin, etc. Such target compound can be used to treat orprevent various diseases, such as gastrointestinal tract disorder,hemophillia, leukemia, liver disease, diabetes, PKU, viral diseases,bacterial diseases, osteoarthritis, enzymatic deficiencies, proteindeficiencies, Alzheimers, infection and cancer. The target compound maybe used to treat a mammal of the same species as that of the milksource, or a mammal of a different species from that from which the milksource is derived.

[0092] Another aspect of the present invention relates to a process forisolating siallylactose from milk, comprising:

[0093] a) optionally flowing the milk from the milk source through afirst cross-flow filtration module to filter out all or at least aportion of bacteria contained therein;

[0094] b) flowing the filtered milk through a second cross-flowfiltration module to separate the milk into a casein-rich fraction and acasein-depleted fraction;

[0095] c) capturing the casein-rich fraction;

[0096] d) flowing the casein-depleted fraction of the milk through athird cross-flow filtration module to form a fraction that is enrichedwith milk proteins selected from the group consisting of albumin,immunoglobulins, β-lactoglobulin, and α-lactalbumin, and a fraction thatis depleted of said milk proteins;

[0097] e) capturing the fraction that is enriched with milk proteinsselected from the group consisting of albumin, immunoglobulins,β-lactoglobulin, and α-lactalbumin;

[0098] f) flowing the fraction that is depleted of said milk proteinsthrough a fourth cross-flow filtration module to form asialyllactose-enriched fraction and a sialyllactose-depleted fraction;

[0099] g) capturing the sialyllactose-enriched fraction; and

[0100] f) discharging the sialyllactose-depleted fraction.

[0101] The milk separation process of the present invention enablesproduction of many improved or entirely new dairy products which may nothave been economically feasible or technically possible prior to theadvent of the present invention, such as: 1) fresh or powdered milk ofcontrolled and regulated protein content, particularly fresh or powderedmilk enriched with one or more specific proteins such as α-lactalbumin,immunoglobulin, and/or lactoferrin, 2) milk protein concentrate, 3)carbohydrate-enriched milk, 4) lactose-depleted milk, 5) bovineimmunoglobulin isolates; 6) drinks, shakes, milk, powders, baby food, orinfant formula enriched with α-lactalbumin, carbohydrate, and/orsialyllactose, 7) purified natural sialyllactose, 8) milk enriched withvarious antibodies, such as Escherichia coli antibody, antibody togastrointestinal tract disorders, 9) reformulated milk of one mammalwhich has a similar composition to another mammal's milk, particularlyreformulated non-human mammalian milk having a similar composition tohuman breast milk, etc.

[0102] Other aspects, features and embodiments of the present inventionwill be more fully apparent from the ensuing disclosure and appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0103]FIG. 1 is a generalized flow chart demonstrating an integralprocess of sequential fractionation of milk components from milk, whey,or colostrum.

[0104]FIG. 2 is a flow chart illustrating a process for sequentialfractionation of milk components from skim milk, and subsequentutilization of the fractioned milk components.

[0105]FIG. 3 is a flow chart showing another process for sequentialfractional of milk components from skim milk.

[0106]FIG. 4 is a flow chart demonstrating a process for sequentialfractionation of whey components from whey, and subsequent utilizationof the fractioned whey components.

[0107]FIG. 5 is a flow chart showing another process for sequentialfractionation of whey components form whey.

[0108]FIG. 6 is a flow chart showing yet another process for sequentialfractionation of whey components from whey.

[0109]FIG. 7 is a flow chart showing still another process forsequential fractionation of whey components from whey.

[0110]FIG. 8 is a flow chart demonstrating a process for sequentialfractionation of milk components from milk.

[0111]FIG. 9 is a flow chart demonstrating another process forsequential fractionation of milk components from milk.

[0112]FIG. 10 is a flow chart showing yet another process for sequentialfractionation of milk components from milk.

[0113]FIG. 11 is a flow chart demonstrating a process for manufacturing3′ sialyllactose-enriched α-lactalbumin.

[0114]FIG. 12 is a flow chart demonstrating a process for manufacturingenzyme-enriched sialyllactose.

[0115]FIG. 13 is a flow chart showing a process for manufacturingsialyllactose.

[0116]FIG. 14 is a flow chart showing a process for manufacturingsialyllactose-enriched whey protein isolate.

DETAILED DESCRIPTION OF THE INVENTION

[0117] Various components and subcomponents of milk differ in theirphysical properties, such as solubility, affinity, molecular weight, andpermeability. For example, milk fat and casein are insoluble in waterand therefore exist in suspended form in milk. The molecular weight ofmilk fat and casein are significantly larger than the molecular weightsof other milk components. Milk also contains soluble whey proteins suchas immunoglobulins, albumin, α-lactalbumin, and β-lactoglobulin, whichhave molecular weights that are smaller than the molecular weights offat and casein, and that are larger than the molecular weights ofcarbohydrates. Carbohydrate components of milk are also characterized bydifferent molecular weights; for example, complex milk carbohydrates,such as 3′ sialyllactose and 6′ sialyllactose, have larger molecularweights than those of simple milk carbohydrates such as lactose.

[0118] Generally, the molecular weights of various milk components canbe ranked as follows:

[0119] Fat and lipids>Insoluble casein>Immunoglobulin andalbumin>β-lactoglobulin>α-lactalbumin>complex carbohydrates such assialyllactose>simple carbohydrates such as lactose.

[0120] The present invention uses cross-flow filtration to physicallyseparate and isolate the above listed components of milk, based on theirdifferent molecular weights and surface chemistry, and thus avoidsintroducing any unnatural chemical additives into the milk products.

[0121] The specificity and speed of separation using cross-flowfiltration modules in accordance with the present invention is affectedby various factors including: a) fluid distribution in the cross-flowmodule, b) channel height of the cross-flow module, c) channel length,d) shear rate, e) membrane pore structure, f) membrane structure, g)membrane chemistry, h) trans-membrane pressure, and i) pressure drop,which is a function of channel length, velocity and solution viscosity.

[0122] The present invention in one aspect optimizes the membraneseparation techniques to provide an integral separation process forfractionation of milk.

[0123] Specifically, the present invention in one embodiment employscross-flow filtration modules with sub-channels that are equidistant tothe inlet and outlet of said modules. Moreover, such cross-flowfiltration modules are characterized by optimal channel height, optimaltransmembrane pressure, optimal membrane pore size and pore structure,optimal membrane chemistry, etc., which characteristics are selected inorder to achieve the best combination of product quality and productionyield.

[0124] For example, shear at the surface of the membrane is critical inminimizing gel layer formation, but excessive shear is deleterious inthe following three key aspects: (1) excessive shear increases energyconsumption, (2) excessive shear interferes with diffusion at themembrane surface, upon which separation process directly depends, (3)excessive shear can deprive certain compounds of their bioactivities. Ittherefore is desirable to maintain shear within an optimal range.

[0125] Furthermore, it is possible to optimize the separate processeswith cross-flow filtration modules of variable channel velocities but ofuniform channel heights, given the fact that most commercial cross-flowmodules are only available in a single channel height. When the channelheight of a cross-flow filtration module is known, shear is directlyproportional to channel velocity of such module for the same solutionbeing flowed through the channel.

[0126] The transmembrane pressure (TMP) of the cross-flow filtrationmembrane can also be optimized after the appropriate tangential velocityhas been determined. Transmembrane pressure is calculated as TMP=(inletpressure+outlet pressure)/2−permeate pressure. The purpose of optimizingthe transmembrane pressure is to achieve maximum permeate flow rate. Thenormal relationship between transmembrane pressure and permeate flowrate can be best represented by a bell curve. Increases in transmembranepressure cause increases in the permeate rate, until a maximum isreached, and after which any further increases in transmembrane pressureresult in decreases in the permeate rate. It is therefore important tooptimize the transmembrane pressure so that the maximum permeate flowrate can be obtained.

[0127] Temperature is another critical factor in optimizing theseparation process. Generally, increases in temperature result inincreased permeate rate of many solutions. Moreover, we have discoveredvia experiment that changes in filtration temperature also result inchanges in the separation outcome, such as the retention and/or passageof a particular solution. For example, when the filtration temperatureis kept within the range of 10° C. to 15° C., lactoferrin will pass(through the membrane of) a cross-flow filtration module manufactured byNorth Carolina SRT, Inc., which comprises BTS100 filtration membranesfrom USF Filtration, San Diego, Calif., but lactoferrin will be retainedby the same filtration module at higher filtration temperatures, whenall other filtration conditions are maintained the same.

[0128] Considering the optimization of membrane separation processes ofthe present invention, additional aspects of the invention relate to theequipment utilized in the aforementioned separation processes as well asthe methods utilized in developing a specific separation process to becarried out in such equipment.

[0129] In Henry B. Kopf's earlier issued U.S. Pat. Nos. 5,593,580,5,342,517, 4,867,876, 5,868,930, 4,882,050, 5,049,268 and 5,232,589,various preferred designs for cross-flow filtration devices, ancillaryequipment and associated methods are disclosed, which are beneficial inseparating and recovering target substances of input fluids. Thedisclosures of all of such prior issued Kopf patents are herebyincorporated herein by reference, in their respective entireties. Suchequipment, methods and operational protocols can be beneficiallyutilized to improve process performance with membranes of any genericformat, such as for example, flat sheets, hollow fibers, spirals,tubular and ceramic.

[0130] In the literature, numerous techniques have been proposed toeffect the separation of target substances using membrane separationswith addition of foreign substances such as acid, base, salt andsolvents. In contrast to these chemical additives-based methods, themethodology of the present invention permits a target substance to beseparated from an input fluid by the simplest mechanical means. In theuse of cross-flow filtration modules of the type described in theaforementioned Kopf patents, the specificity and speed of a desiredseparation is effected by a) fluid distribution in the cross-flowmodule, b) channel height of the cross flow module, c) channel length,d) shear rate, e) membrane pore structure, f) membrane structure, g)membrane chemistry, h) trans-membrane pressure, and i) pressure drop,which is a function of channel length, velocity and solution viscosity.

[0131] The approaches by others involving various additives andmanipulations of transmembrane pressure appear to be predicated onovercoming problems created by poor distribution of flow within thecross-flow module. It is not to say that the addition of salts andsolvents do not have a place in separation but without proper flowdistribution the membrane separation cannot be optimally operated norwill cleaning techniques be fully beneficial. It will be appreciated,based on the disclosure herein, that numerous heretofore expensive ordifficult separations are rendered far simpler and more economical byemploying the techniques described herein.

[0132] Thus, the invention relates in another aspect to optimizing themembrane separation process, comprising:

[0133] selecting a cross-flow membrane module wherein the distance fromthe inlet port to the outlet port is equidistant from the inlet tooutlet for each sub-channel of the device, i.e., each sub-channel is ofa same dimensional character;

[0134] selecting an optimal channel height;

[0135] selecting an optimal shear rate and/or channel velocity;

[0136] selecting an optimal transmembrane pressure;

[0137] selecting an optimal membrane pore size;

[0138] selecting an optimal membrane chemistry;

[0139] selecting an optimal membrane pore structure;

[0140] selecting an optimal temperature;

[0141] selecting an optimal channel length; and

[0142] selecting an optimal pressure drop which is the composite of

[0143] the optimal channel height;

[0144] the optimal shear rate and/or channel velocity;

[0145] optimal channel length; and

[0146] the viscosity of the solution being filtered.

[0147] As previously described the distribution of flow is critical fordevelopment and scale-up of any separation technique, since withoutuniform distribution of flow, the device will not be capable of properprocess scale-up or suitable cleaning. The intriguing caveat of uniformflow is that when a substance can be separated only in a narrow range ofparameters, the uniform device can be uniformly wrong as readily asuniformly correct.

[0148] Due to the fact that the cross-flow filtration devices disclosedin the aforementioned Kopf patents and preferably used in the practiceof the present invention are relatively new and less widely utilized incomparison to cassettes commercially available from Millipore andPall-Filtron, spiral wound elements commercially available from Koch andOsmonics, and hollow fibers commercially available from Koch-Romicon andA/G Technology, many applications we have encountered were previouslyattempted with one or more of these prior art cross-flow filter devices.

[0149] It has been documented that in the prior art devices, in casesinvolving permeation of a target substance away from a larger species,such as in isolation and recovery of a secreted protein from cellculture fluid, the higher the passage of protein encountered on theprior art device the easier the separation.

[0150] In other words, when the protein rejection of the prior art,hollow fiber, cassette or spiral cross-flow module is fifty percent(50%), roughly half of the various conditions in the prior art deviceare appropriate for separation. Given the non-uniform flow distributionof the prior art devices, this correlates with the fact that the targetsubstance can be separated from the larger substances by numerousoperating parameters. Accordingly, the separation would be deemed easy.In contrast, a separation in which the protein rejection of the priorart hollow fiber, cassette or spiral cross flow module is ten percent(10%) correspondingly means that less than ten percent of the variousconditions inside the prior art device are appropriate for separation.Given the non-uniform flow distribution of the prior art devices, thiscorrelates to the fact that the target substance can be separated fromthe larger substances only under highly specific conditions, and theseparation therefore is deemed a difficult separation.

[0151] Selecting a channel height can be performed mathematically orempirically by trial and error. In most cell fermentation applications,trial and error has been more appropriate due to the fact that theviscosity of the cell broth or product solution is rarely known, thecell count and cell viability are highly variable, and the solution isfrequently non-Newtowian. The objective of channel selection is tominimize channel height with three critical stipulations: first, thechannel must be sufficiently high to allow the unrestricted passage ofany larger material such as clumped cells; second, the channel shouldnot cause excessive pressure drop and loss of linear efficiency; andthird, the channel should be sufficiently high as to allow the properangle of attack for substances to encounter the membrane pore and passthrough the pore. The optimal channel height is dependent on the lengthand viscosity of the solution.

[0152] Several notable observations have been made in initial trials andprocess scale-up, as discussed below.

[0153] For cell suspensions having an optical density (OD) of 2 to 500,and a path length of 6 to 12 inches, start with a channel height between0.4 to 0.75 mm. If the inlet pressure is above 15 PSIG at a velocity of2.0 M/sec, then the channel is too thin.

[0154] For cell suspensions having an optical density (OD) of 2 to 500,and a path length of 6 to 12 inches, start with a channel height between0.4 to 0.75 mm. If the inlet pressure is below 5 PSIG at a velocity of2.0 M/sec the channel is too high.

[0155] For cell suspensions having an optical density (OD) of 2 to 500,and a path length of 25 to 40 inches, start with a channel heightbetween 0.7 to 1.0 mm. If the inlet pressure is above 15 PSIG at avelocity of 2.0 M/sec, the channel is too thin.

[0156] For cell suspensions having an optical density (OD) of 2 to 500,and a path length of 25 to 40 inches, start with a channel heightbetween 0.7 to 1.0 mm. If the inlet pressure is below 5 PSIG at avelocity of 2.0 M/sec, the channel is too high.

[0157] For non-particulate-containing fluids such as protein solutionshaving a concentration of 1 to 20 percent by weight, and a path lengthof 6 to 12 inches, start with a channel height between 0.2 to 0.5 mm. Ifthe inlet pressure is above 15 PSIG at a velocity of 3.0 M/sec, thechannel is too thin.

[0158] For non-particulate-containing fluids such as protein solutionshaving a concentration of 1 to 20 percent by weight, and a path lengthof 6 to 12 inches, start with a channel height between 0.2 to 0.5 mm. Ifthe inlet pressure is below 5 PSIG at a velocity of 3.0 M/sec, thechannel is too high.

[0159] For non-particulate containing fluids such as protein solutionshaving a concentration of 1 to 20 percent by weight, and a path lengthof 25 to 40 inches, start with a channel height between 0.4 to 1.0 mm.If the inlet pressure is above 15 PSIG at a velocity of 3.0 M/sec, thechannel is too thin.

[0160] For non-particulate containing fluids such as protein solutionshaving a concentration of 1 to 20 percent by weight, and a path lengthof 25 to 40 inches, start with a channel height between 0.4 to 1.0 mm.If the inlet pressure is below 5 PSIG at a velocity of 3.0 M/sec, thechannel is too high.

[0161] Shear at the surface of the membrane is critical in minimizinggel layer formation, but excess shear is deleterious in at least threekey aspects: first, it increases energy consumption costs; second,excess shear and the resulting pressure has been demonstrated tointerfere with separations which appear to be based on diffusion at themembrane surface; and third, shear can result in damage to cells andimpairment of the bioactivity of certain compounds.

[0162] It is apparent that the benefits of shear are readily observedwithin a specific range for each process and that shear rates outsidethat range are highly destructive.

[0163] Before progressing in the explication of the optimizationprocess, it must be pointed out that the shear stability of thesubstances in solution or suspension, is a key element in shearoptimization. Only through accurately calculating and charting thespecific shear rates utilized during optimization can the true benefitsof shear optimization become apparent. In protein concentrationprocesses, it is graphically clear that the higher the shear, the higherthe membrane flux, with two striking observations.

[0164] First, there is a minimum shear value that minimizes thegel-layer formation. This minimum shear can be best demonstrated for anyspecific solution by first running the device at an excessively highshear rate and then systematically lowering the shear incrementallyuntil the resultant flux decay of each incremental reduction in shear isdisproportional to the reduction in shear. Given the repeatedobservation during cross-flow concentration applications that increasingthe shear increases the flux, the maximum flux for solutions is clearlygoverned by the law of diminishing returns, where at some pointincreases in shear provide lower increases in flux.

[0165] For concentration applications, it can be stated that there is aminimum shear required to keep the membrane clean through minimizing thegel-layer formation, as well as a maximum shear which is determined bythe cost of energy required to marginally increase flux.

[0166] For separation applications it can be stated that there is aminimum shear required to minimize the gel-layer formation and allow thepassage of a target substance, as well as a maximum shear thatinterferes with the passage of a target substance, even though thehigher shear results in higher water flux rates.

[0167] Furthermore, it is possible to develop processes based on channelvelocity, given that most cross-flow end users tend to work with asingle channel height based on past experiences, and the predominance ofcross-flow modules that are only available in a single channel height.

[0168] When working with a single device of uniform height, shear isdirectly proportional to channel velocity for the same solution. Inconcentration applications, the end user should install a flow meter onthe permeate port and record the maximum flux obtained at reasonablecross-flow velocities between 1 and 4 M/sec for devices with channelheights between 0.5 mm and 1.0 mm. In separation applications, the enduser should assay the passage of the target material(s) at cross-flowvelocities between 0.5 and 2.5 M/sec for devices with channel heightsbetween 0.5 mm and 1.5 mm. In protein separation applications inparticular, the user should:

[0169] design the system piping such that the retentate return line fromthe cross-flow module creates no back pressure on the membrane;

[0170] select a channel height between 0.5 and 1.5 mm; and

[0171] assay the permeate and retentate simultaneously at channelvelocities every 0.1 M/sec between 0.5 and 2.0 M/sec to find the optimumpassage (minimum rejection).

[0172] It is far more accurate to measure and scale-up membraneperformance based on calculating the shear. Shear calculations requirethe fluid viscosity as well as the hydraulic diameter of the crossflowdevice being utilized.

[0173] The preferred shear rates for different applications are asfollows:

[0174] the optimal permeate rate for concentration procedures utilizingultrafiltration membranes is achieved in the range of 10,000 to 50,000(/sec), and in most circumstances a shear of 15,000 to 32,000/sec willprovide satisfactory results;

[0175] the optimal separation of proteins utilizing membrane with porestructures greater than 0.05 micron is achieved in the range of 3,000 to30,000 (/sec), and in most circumstances a shear of 4,000 to 16,000/secwill provide satisfactory results;

[0176] the optimum permeate rate for cell concentrations is achieved inthe range of 10,000 to 65,000 (/sec), where the larger pore sizemembranes require the higher shear rates; and

[0177] the shear rate of 32,000/sec often provides excellent results forprotein concentrations with membranes from 1,000 to 100,000 daltons.

[0178] Given the difficulty for most membrane users to calculate shearrates due to a lack of sufficient information regarding the hydraulicdiameter of various devices, using velocity calculations will besufficient for process optimization and scale-up when a single channelheight is utilized.

[0179] Flat Sheet Devices:

Velocity (cm/sec)=Volumetric Flow Rate (LPM) divided by Channelhydraulic diameter (cm)×Number of Channels×60×0.001

V (cm/sec)=LPM/D _(H)×Number of Channels×60×0.001

V Meter/sec=V (cm/sec)/100

[0180] Hollow Fibers:

Velocity (cm/sec)=Volumetric Flow Rate (LPM) divided by Fiber hydraulicdiameter (cm²)×Number of Fibers×60×0.001

V (cm/sec)=LPM/D _(H) (cm)×Number of Fibers×60×0.001

V M/sec=V cm/sec/100

[0181] Volumetric Flow Rate Calculations

[0182] Flat Sheet Devices:

Volumetric Flow Rate (LPM)=Channel hydraulic diameter (cm)×Number ofChannnels×Velocity (cm/sec)×60×0.001

LPM=D _(H)×Number of Channels×V (cm/sec)×60×0.001

GPM=LPM/3.785

[0183] Hollow Fibers:

Volumetric Flow Rate (LPM)=Fiber hydraulic diameter (cm)×Number ofFibers×Velocity (cm/sec)×60×0.001

LPM=D _(H) (cm)×Number of Fibers×V (cm/sec) 60×0.001

GPM=LPM/3.785

[0184] The optimization of transmembrane pressure (TMP) can only beperformed after the appropriate tangential velocity has been determined.Transmembrane pressure is calculated as TMP (inlet pressure+outletpressure)/2−permeate pressure. It is imperative that the tangentialvelocity (flow rate) be monitored during the optimization oftransmembrane pressure, since increasing the pressure normally decreasesthe output of most pumps due to slippage. The objective of theoptimization of transmembrane pressure is to define the correlation oftransmembrane pressure to permeate flow rate. The normal relationship isa traditional bell curve. A graph of transmembrane pressure versuspermeate flow rate should resemble a bell curve. Increases intransmembrane pressure cause increases in the permeate rate until amaximum is reached, and thereafter further increases in transmembranepressure result in decreases in the permeate rate. The reason for thisresult is that the decreasing flow rate, resulting from highertransmembrane pressures, is the result of gel layer and/or membranecompression.

[0185] The procedure is set out below:

[0186] (1) Operate the system in total recycle mode at the optimumtangential velocity for sufficient time, typically fifteen minutes, forany gel layer to accumulate.

[0187] (2) Measure the permeate rate. This is the Base Rate.

[0188] (3) Increase the transmembrane pressure by 3 PSIG and measure thepermeate rate immediately and after five minutes at the newtransmembrane pressure. Compare the permeate rates to the base rate. Ifthe rates have increased go to Step 4. If the rate decreases go to step5.

[0189] (4) Repeat steps 2 and 3 until the permeate rate no longerincreases during each step or does not hold that increase for fiveminutes.

[0190] (5) The optimum transmembrane pressure is the last pressurereading where the increase in pressure result in an increase in permeaterate.

[0191] In separation applications, the end user should assay the passageof the target material(s) at TMP's between 2 and 15 PSIG where thecross-flow velocity is optimized between 0.5 and 2.5 Msec for deviceswith channel heights between 0.5 mm and 1.5 mm.

[0192] In protein separation applications in particular, the user shouldfollow the procedure set out below:

[0193] design the system piping such that the retentate return line fromthe cross-flow module creates no back pressure on the membrane;

[0194] from optimization of shear section above, select a channel heightbetween 0.5 and 1.5 mm;

[0195] the channel velocities should be between 0.5 and 2.0 M/sec;

[0196] increase the TMP by closing the backpressure valve such that theTMP increaes in one pound increments; and

[0197] sample the retentae and permeate simultaneously at each one-poundincrement of TMP to find the optimum passage (minimum retention) of thetarget substance.

[0198] Selecting and optimizing the channel length has been totallyimpractical if not an impossible task until the advent of the currentinvention. The inherent difficulty of optimizing the channel length inprior art devices has been three-fold: first, the devices such asspirals were designed to maximize membrane utilization based on thewidth that membranes could be cast rather than any other factor; second,increases in channel length for devices such as cassettes resulted inenormous increases in pressure drop due to the predetermined channelgeometry imposed by the retentate screen; and third, plate and framedevices, such as for example Pleidae by Rhodia, France, use fixed moldedplates which are manufactured in a single length and cannot be changedwithout manufacturing a new mold.

[0199] The present invention eliminates these prior art restrictions byproviding the ability to select the channel length by utilization of aninfinitely variable retentate sheet that is cut to length from anappropriately manufactured film, selected from a variety of standard orstarting point thicknesses. Likewise, the membrane sheets and permeatesheets are cut to matching lengths and laminated into a stackedcassette.

[0200] There undoubtedly are many ways of selecting the optimum membranefor any given process, yet it appears the most reliable method of usingmembranes is to consider the manufacturer's specified pore size as atheoretical starting point which then is modified by the solution andthe operating conditions. As a result of numerous trials, we havedeveloped a practical parameter that we have termed the coefficient ofrejection.

[0201] Coefficient of Rejection (CRV)

[0202] Membranes have a rejection characteristic (value) that is firstorder and is defined by the size, charge and shape of the pore. Forsimplicity the CRV, coefficient of rejection value, is the stated poresize provided by the manufacturer. In purifying a product of interestthe CRV of a membrane is more important for separation applications ascompared to concentration applications. The rules below specificallyrelate to separation applications. These effects will vary inconcentration applications.

[0203] The CRV of a membrane is subject to the velocity of thetangential flow operation. Empirical evidence suggests that the neutralpoint of any membrane can occur in two zones, the first zone being thepoint at which the transmembrane pressure and/or shear compress the gellayer and the CRV increases, and the second zone occurring where the TMPand velocity minimize the shear and the CRV decreases. The neutral point(NP) is defined as the point where a membrane freely passes particles0.5 times the stated pore size, NP=0.5(Pore Size).

[0204] Therefore:

[0205] the effective CRV of a typical micro porous membrane is greaterthan the pore size, for velocities greater than 1.5 M/sec and less than3.0 M/sec.; and

[0206] the effective CRV of a typical ultrafiltration membrane isgreater than the pore size, for velocities greater than 1.5 and lessthan 3.0 M/sec.

[0207] Example: A 0.3 p particle may freely pass a 0.45μ polymericmembrane when the velocity is between 1.5 and 4.0 M/sec but not forvelocities between 0.5 and 1.5 M/sec or 4.5 and 12 M/sec.

[0208] Example: A 45,000 MW protein may freely pass a 0.2μ membrane forvelocities of 0 to 1.0 M/sec but be significantly retained when thevelocity is increased above 1.5 M/sec. In the same experiment, it wasdocumented that protein passage was above 90% for velocities between 0.8and 1.5 M/sec and 25% for a velocity of 2.0 M/sec. Additionally, thissame protein had 65% membrane transmission through a 100,000 MW membraneat velocity of 1.0 M/sec.

[0209] Further:

[0210] the CRV of a membrane is proportional to the molarity of thesolution;

[0211] the greater the solute concentration, the greater the CRV; and

[0212] the lower the solute concentration, the smaller the CRV.

[0213] Example: A membrane may have a stated pore size of 500,000 MW butwill retain proteins of 110,000 MW in cell suspension with an OD over100 and pass the same 110,000 MW protein when the OD is less than 50.

[0214] A more detailed understanding of how concentration affects theCRV of a membrane will be gained from the following three additionalexamples.

[0215] Example: During experiments passing whey proteins such asLactoferrin, α-lactalbumin and β-lactoglobulin away from casein using aBTS100 membrane, USF Filtration, San Diego, Calif., when installed in aNorth Carolina SRT, Inc. cross flow filtration module, it was observedthat the milk source could first be concentrated using a tightultrafilter prior to the BTS100 for improved protein passage through theBTS100, inasmuch as the CRV for the whey proteins was significantly low.A commercial application of this observation would be that milk could befirst concentrated by any suitable means such as membrane filtrationand/or evaporation, and the concentrate or some portion thereof couldthen be processed by a BTS100 membrane module, or a suitable alternativemembrane, for improved whey protein harvest. In these same experiments,it was noted that the optimal velocity was between 0.8 and 1.5 M/sec forthe optimal protein passage.

[0216] Example: When separating an excreted target protein from a cellculture or an intracellular protein from a cell lysate by cross-flowmicrofiltration, the concentration of the cells or cell debrisinvariably prevents the passage of the target protein into the permeate,even though the protein freely passes through the membrane in theearlier part of the process . This fact does not prevent the use ofcross-flow microfiltration, but rather determines it specificapplication. First, rather than merely concentrate the cell or cellulardebris, the investigator can set the velocity at 1.0 M/sec and monitorthe CRV of the membrane, assaying the passage of the target protein atset volumetric increments into the permeate during concentration, andbeginning diafiltration of the target protein at the point just prior tothe CRV of the membrane preventing the passage of the target protein.

[0217] Example: A preferred method for recovering an excreted targetprotein from a cell culture or an intracellular protein from a celllysate is to perform two filtrations simultaneously. In the firstfiltration, the cells or cellular debris is continuously diafilteredutilizing the membrane with the tightest pore size which passes thetarget protein. The second filtration concentrates the target proteinutilizing the most open pore size that concentrates the target protein.An optional adjunct to this process is to utilize the permeate of thesecond filter to be the diafiltrate of the first filter. This processresults in the highest yield and lowest cost as compared to alternativemembrane and centrifugation procedures, by eliminating the large tanknormally required to collect the permeate of the first filter and thecost of the diafiltrate solution. This method is enormously useful forperforming any number of separations, including, without limitation,milk, juice, wastewater, bacteria, mammalian cells, virus, viralparticles, antigens, antibodies, and plant and tissue extracts.

[0218] Additionally:

[0219] the CRV of a membrane for a given species is minimized at theisoelectric point of the species.

[0220] Example: Albumin is readily retained by membranes as large as 200kD at a pH of 7.4, and albumin freely passes membranes as small as 100kD at a pH of 4.8.

[0221] Further:

[0222] the CRV of a membrane for a given species can be minimized byutilization of salt concentrations that dissociate the species ofinterest from other solutes.

[0223] Example: Pasteurella and Pneumoccal cell wall fragments(polysaccharide vaccines) are readily separated from whole cells in thepresence of high NaCl concentrations that dissociate the polysaccharidefrom the cell wall. Fibrinogen readily passes 0.6μ membranes in thepresence of sodium citrate, which prevents clotting and fibrinogencross-linking.

[0224] Still further:

[0225] the CRV value of a membrane is directly affected by the bindingproperties of the polymer; as simple as this sounds, the particularbenefits associated with any single membrane polymer, such as lowbinding membranes, are far from clear; we have encountered variousapplications where membranes had CRV values that were 0.1×themanufacturer's stated pore size.

[0226] Example: Sialyllactose can be isolated from both milk and whey byfirst separating the sialyllactose from the whey proteins with a lowsurface charge membrane such as regenerated cellulose and thenconcentrating the sialyllactose away from the lactose with a highsurface charge polyethersulfone membrane.

[0227] Additionally:

[0228] the CRV of a membrane for a given species can be minimized byutilization of a temperature that dissociates the species of interestfrom other solutes.

[0229] Example: Lactoferrin will pass a BTS100 membrane, USF Filtration,San Diego, Calif., when installed in a North Carolina SRT, Inc.cross-flow filtration module between the temperatures of 10 and 15degrees Centigrade, but is retained by the membrane above this range atthe prescribed velocities in the experiments.

[0230] The role of temperature as demonstrated in the example citedabove is also critical in both concentration and separation. It isconventional wisdom that increases in temperature produce increasedpermeate rates of many solutions. In our experiments, we have discoveredthat changes in temperature can produce several additional,heretofore-undocumented results.

[0231] Further:

[0232] changing the temperature of a solution changes properties withinthe membrane/solution profile such that the retention and/or passage ofa given species is changed.

[0233] Example: Lactoferrin will pass a BTS100 membrane, USF Filtration,San Diego, Calif., when installed in a North Carolina SRT, Inc.cross-flow filtration module between the temperatures of 10 and 15degrees Centigrade but is retained by the membrane above this range atthe prescribed velocities in the experiments.

[0234] Still further:

[0235] changing the temperature of a solution changes the rejectioncharacteristics of a membrane.

[0236] Example: Increasing the temperature of milk during processingwith a BTS100 membrane, USF Filtration, San Diego, Calif., wheninstalled in a North Carolina SRT, Inc. cross-flow filtration moduleincreases the permeate rate and the total protein passage into thepermeate.

[0237] In addition to the foregoing:

[0238] changing the temperature of a solution changes properties withinthe membrane/solution profile such that the retention and/or passage ofa given species can change with respect to its proportion to otherspecies in the solution.

[0239] Example: Increasing the temperature of milk during processingwith a BTS100 membrane, USF Filtration, San Diego, Calif., wheninstalled in a North Carolina SRT, Inc. cross-flow filtration moduleincreases the total protein passage but it also changes the proportionof α-lactalbumin to β-lactoglobulin in the permeate.

[0240] Therefore, with respect to perfecting any separation process withregard to temperature, it is advisable to vary the temperature between4° C. and 60° C. where appropriate, and to measure changes in permeateflux rate, total solute passage and the proportions of the solutepassing through the membrane.

[0241] There are multiple practical applications and benefits inherentin varying the channel height and length of a filter module, in modulesof such type as are described in the U.S. Patents issued to Henry B.Kopf, as discussed hereinabove, and incorporated herein by reference intheir respective entireties, and in modules described in Henry KopfIII's co-pending U.S. patent application Ser. No. 09/818,823 filed Mar.27, 2001 for “INTEGRAL GASKETED FILTRATION CASSETTE ARTICLE AND METHODOF MAKING THE SAME” and incorporated herein by reference in itsentirety. A significant benefit is the optimization of shear andpressure drop within a single filter module and/or process. In addition,this same optimization protocol is beneficial to each filter module in amultistage or multi-step process, in which each filter can and should beoptimized individually, and aggregately as a part of the entire system.

[0242] Example: In a two step process such as recovering a targetprotein excreted by a genetically engineered cell line, it isadvantageous to vary the channel lengths and channel heights. In thefirst step, a microporous membrane filter would be optimal with a 0.875mm channel and a path length equivalent to the SEPTOPORT™ Filter Module,commercially available from North Carolina SRT, Inc., Cary N.C. In thesecond step, an ultrafiltration membrane using a lower 0.75 mm channelheight and a longer path length equivalent to the ECON™ Filter Modulecommercially available from North Carolina SRT, Inc., Cary N.C., wouldbe optimal.

[0243] Specifically, the first step is optimized for a viscous cellclarification requiring a relatively higher channel and short pathlength, and the second step is optimized for concentrating a diluteprotein excreted by the cell into the culture media, which is moreoptimally performed with a lower channel height, higher shear, and alonger path length due to the lower viscosity.

[0244] Example: In a multistage system such as a large scale dairysystem employed to separate whey proteins from casein in milk, it isadvantageous to utilize a filter module of higher channel height of thesame length, or a filter module of the same channel height in a shorterchannel length in the latter stage filter modules, to adjust for theincrease in viscosity as the casein concentration increases. In thisexample, it is appropriate to note that the deciding factor, betweenlowering or raising the channel height, or lengthening or shortening thepath lengths of the modules to respectively increase or decrease shearand/or raise or lower pressure drop, follows the guidelines set forthabove for operating a single filter module or a single step process.

[0245] The clear advantage to the end user is that the dimensionalcriteria and algorithmic approaches discussed hereinabove, inapplication to the filtration modules disclosed in the aforementionedU.S. patents of Henry B. Kopf and the pending U.S. patent application ofHenry Kopf III, provides the method and equipment necessary forselection and optimization of the most efficient channel height andlength for individual filter modules, as well as each filter modulewithin multi-stage or multi-step systems.

[0246] The disclosures herein are directed to illustrative methods andequipment useful in the separation of liquids, gases, and mixtures andsuspensions of various liquids, gases, solids and solvents, howevermixed or suspended. It also is intended that the equipment and methodsof the invention be broadly used and applied for both stand-alonefiltration modules, as well as complexes or integrated installations offiltration modules, for any given separation protocol.

[0247] The potential uses of the invention in the pharmaceutical,commercial, enzyme production, dietary supplement, vitamin, food,beverage, waste recovery, environmental, neutraceutical and dairyindustries are enormous in variety and extent of applications, due tothe fact that the process does not alter the natural state of thecomponents, and it also allows the individual components to be utilizedseparately as well as in combination, in useful formulations of enrichedcomponents for specific uses.

[0248] Furthermore, the use of equipment and methodology for continuousfermentation of the lactose or sugar stream of any one of theaforementioned separated milk product streams, has potential for furtherenhancing the economic feasibility of the overall process, as well aslowering the environmental impact of releasing excess lactose and otherhigh bacterial oxygen demand substances into the environment.

[0249] By optimizing membrane separation techniques, we have developedan integral separation process for fractioning milk into its variousnutritional components, including for example proteins, carbohydrates,and minerals that are essential for normal growth and development ofinfants and possess important nutritional or therapeutic values foradults.

[0250] For example, beta-lactoglobulin has numerous binding sites forminerals (particularly for calcium and zinc), fat-soluble vitamins, andlipids, and can be used to incorporate desirable lipophilic compoundssuch as tocopherol and vitamin A into low-fat products.Alpha-lactalbumin accounts for 28% of the total protein in human milk,and addition of bovine alpha-lactalbumin is strongly advocated to“humanize” infant formulas and create other products for people withlimited or restricted protein intakes.

[0251] Immunoglobulins, such as IgG1, IgG2, IgA, and IgM, providepassive immunity to infants as well as adults, and therefore have hightherapeutic values. Serum albumin binds fatty acids as well as othersmall molecules. Glycomacropeptide (GMP), the glycosylated portion ofcaseinomacropeptide, can suppress appetite via stimulation of thepancreatic hormone cholecystokinin release, making it useful formanufacturing of appetite-suppressant products or diet aids.

[0252] Siallyllactose, which is the main siallylated compound in humanmilk, has inhibitory effects on diarrhea induced by cholera toxin, andtherefore is therapeutically valuable in preventing or treatingdiarrhea.

[0253] Isolation and purification of these milk components therefore areimportant for full utilization of milk or milk-based nutrition sources.

[0254] Referring now to the drawings, FIG. 1 is a generalized flow chartdemonstrating an integral process of sequential fractionation of milkcomponents.

[0255] Feed (which may be milk, or skim milk, whey, or other milk-basedfluids) is flowed through cross-flow filtration module 1 to generate aretentate fraction A, which may include bacteria, milk fat, or casein.

[0256] The permeate fraction generated by the cross-flow filtrationmodule 1 (passed through the membrane therein) is then flowed throughfiltration module 2 to form a retente fraction B, which may include wheyprotein isolates (WPI) including small particles of milk fat or caseinthat are not retained by filtration module 1. Alternatively, theretentate fraction B generated by filtration module 2 may includelactoferrin concentrate or immunoglobulin G and albumin concentrate.

[0257] The permeate fraction from the cross-flow filtration module 2subsequently passes through cross-flow filtration module 3 and forms aretentate fraction C and D, which may be the mixture of β-lactoglobulinand α-lactalbumin. Retentate fraction C and D can be further separatedby another filtration module 4 to form isolated fraction C (which may beβ-lactoglobulin) and D (which may be α-lactalbumin).

[0258] In one specific embodiment of the present invention, theretentate fraction B (which contains whey protein isolates) generated,i.e., formed by membrane filtration, by filtration module 2 can be addedinto the retentate fraction C and D (which contains β-lactoglobulin andα-lactalbumin) from filtration module 3, so as to form β-lactoglobulinand α-lactalbumin-enriched whey protein isolates, as a novel nutritionproduct.

[0259] The permeate fraction generated by the cross-filtration module 3then is passed downstream through filtration module 5. A retentatefraction E is formed by filtration module 5, and this retentate fractionmay contain complex carbohydrates such as 3′ and 6′ sialyllactose.

[0260] The permeate fraction generated by filtration module 5 then canbe passed through filtration module 6, which generates a retentatefraction F containing lactose, and a permeate fraction constitutedmainly of water. The water generated by filtration module 6 can berecycled for purpose of cleaning upstream filtration modules, as shownby the arrow heads with dashed lines.

[0261] The lactose-enriched retentate F of filtration module 6 can befurther subjected to a fermentation process and then passed through abioreactor membrane device 7, to form a retentate fraction G that can beused as an animal feed. The permeate fraction from the bioreactormembrane device 7 can then be fractionated by another membrane device 8to concentrate secreted substances H from the cell mass of bioreactordevice 7, providing a clean lactic acid fraction. Alternatively, asshown by the dotted lines, membrane device 8 could be utilized tofurther concentrate the cell mass from bioreactor device 7 and produce acell-free permeate of commercial value.

[0262]FIG. 2 shows a separation process for fractionating skim milk,according to one embodiment of the present invention.

[0263] The skim milk feed, from which the fatty component of milk (i.e.milk fat and lipids) has been removed, is flowed through filtrationmodule 21 to form a casein-rich retentate fraction and a casein-depletedpermeate fraction. The separation of casein from the other components ofmilk can be effectuated by incorporating into the filtration module 21 afiltration membrane of average pore size in a range of from about 100 KDto about 3000 KD.

[0264] The filtration membrane can be cellulose-based, polymer-based, orceramic-based. Preferably, such filtration membrane is cellulose-basedand comprises a suitable cellulosic membrane material, such as forexample, cellulose, cellulose acetate, or regenerated cellulose. It isespecially preferred that such filtration membrane be a regeneratedcellulose membrane having an average pore size in a range of from about100 KD to about 1,000 KD. The filtration membrane for separating caseinalternatively can be characterized by retentate molecular weight withina range of from about 100,000 to about 3,000,000 MW, or by a bubblepoint in a range of from about 65 to about 120 psig, preferably fromabout 80 to about 100 psig. In one specific embodiment of the presentinvention, a BTS 100 membrane manufactured by U.S. Filters (San Diego,Calif.) is used. The BTS 100 membrane is a polymeric membrane having abubble point of 100 psig.

[0265] The casein-depleted permeate fraction generated by filtrationmodule 21 then is passed through another filtration module 22 to form aretentate fraction that is enriched with immunoglobulin G (IgG) andalbumin, and a permeate fraction that is depleted of albumin and IgG.The separation of albumin and IgG from the other components of milk canbe effectuated by incorporating into the filtration module 22 apolymeric or cellulosic filtration membrane having retentate molecularweight with a range of from about 50,000 to about 300,000 MW. The RC 100membrane manufactured by Nadir Filtration GmbH (Wiesbaden, Germany) isparticularly useful for the purpose of separating IgG and albumin fromcasein-depleted whey.

[0266] The permeate fraction from filtration module 22, which isdepleted of IgG and albumin, then can be flowed from filtration module22 through a cross-flow filtration module 23 for the purpose ofseparating β-lactoglobulin from other components in such permeatefraction. A cellulosic filtration membrane having retentate molecularweight within the range from about 10,000 to about 50,000 MW can beincorporated into filtration module 23. In a preferred embodiment, an RC30 membrane manufactured by Nadir Filtration GmbH (Wiesbaden, Germany)is used for separation of β-lactoglobulin.

[0267] The permeate fraction from filtration module 23 is depleted ofβ-lactoglobulin. It can be subsequently used to produce α-lactalbumin,by passing such permeate fraction through a filtration module 24 thatincorporates a polymeric or cellulosic filtration membrane having aretentate molecular weight within a range of from about 1,000 to about20,000 MW. Preferably, filtration module 24 contains a cellulosicmembrane having a retentate molecular weight of about 5,000 MW. Morepreferably, an RC 5 membrane manufactured by Nadir Filtration GmbH(Wiesbaden, Germany) is used for separation of α-lactalbumin.

[0268] Filtration module 24 generates an α-lactalbumin-depletedpermeate, which can be subsequently flowed through filtration module 25for separation of complex carbohydrates such as sialyllactose (SL).Filtration module 25 comprises a polymeric membrane having a retentatemolecular weight within a range of from about 500 to about 10,000 MW,which forms a sialyllactose-rich retentate and a sialyllactose-depletedpermeate. The filtration membrane incorporated in filtration module 25preferably is characterized by a retentate molecular weight within arange of from about 800 to about 5,000 MW, more preferably from about1,000 to about 3,500 MW, and most preferably from about 1,000 to about3,000 MW. PES 2.5 kD membranes manufactured by Osmonics Co. (Minnetonka,Minn.) are particularly useful for isolating and separatingsialyllactose.

[0269] The sialyllactose-depleted permeate from filtration module 25comprises mainly simple carbohydrates, such as lactose, and water.Lactose (i.e., milk sugar) accounts for 63-75% by weight of dry wheypowder and is a valuable nutrition source. It therefore is desirable tofurther isolate and purify lactose from water for further uses, by usingan additional filtration module 26 that incorporates a polymeric orcellulosic reverse osmosis membrane. Such reverse osmosis membranepreferably is characterized by a NaCl rejection rate of 80% or greater,and is capable of retaining 98% or greater of the lactose.

[0270] The isolated lactose from filtration module 26 can be furtherused to produce culture media. It can also be subjected to afermentation process, using a bioreactor membrane device 27 that ischaracterized by a pore size between about 10,000 MW and about 0.45micron. The fermented lactose can then be passed through a filtrationmembrane 28, which forms a retentate fraction, containing cell massconcentrates, and a permeate fraction, containing lactic acid, that canbe used to manufacture plastics, vitamin B, and other bioactiveproducts.

[0271]FIG. 3 depicts a separation process for fractionating skim milk,according to a different embodiment of the present invention from thatof FIG. 2.

[0272] The skim milk feed is passed first through filtration module 31for separation of casein. Permeate from filtration module 31 then ispassed through filtration module 32 to form a retentate fraction,including whey protein isolates (WPI) containing IgG, albumin,β-lactoglobulin, α-lactalbumin, etc. Filtration module 32 may comprise apolymeric or cellulosic filtration membrane having retentate molecularweight of from 5,000 to about 40,000 MW, more preferably from about5,000 to about 20,000 MW, and most preferably about 5,000 MW. An RC 5membrane manufactured by Nadir Filtration GmbH (Wiesbaden, Germany) isuseful for the purpose of separating WPI.

[0273] The WPI-depleted permeate fraction from filtration module 32 canbe subsequently flowed through filtration modules 33 and 34 forseparation of sialyllactose and lactose, respectively.

[0274]FIG. 4 is a flow chart for a separation process for fractionatingwhey that has been depleted of casein. The whey feed is flowed through afirst cross-flow filtration module 41 to form a retentate fraction,which is enriched with IgG and albumin, and a permeate fraction that isdepleted of IgG and albumin. The retentate fraction that is enrichedwith IgG and albumin is captured (recovered), while the permeatefraction that is depleted of IgG and albumin is subsequently passedthrough a second cross-flow filtration module 42, for separation ofβ-lactoglobulin, and a third cross-flow filtration module 43, forseparation of α-lactalbumin.

[0275] Permeate from filtration module 43 is depleted of most wheyproteins and can be sequentially passed through filtration modules 44and 45 for separation of sialyllactose and lactose, respectively. Thelactose retained by filtration module 45 can then be used to produceculture media, or alternatively it can be subjected to fermentation andfiltration processing to produce a cell mass concentration formanufacturing of animal feed, and lactic acid for manufacturing ofplastics and vitamin B.

[0276]FIG. 5 illustrates another separation process for fractioning wheyinto whey protein isolates (WPI) or whey protein concentrates (WPC),sialyllactose, and lactose, using sequentially arranged cross-flowfiltration modules 51, 52, and 53.

[0277]FIG. 6 depicts yet another separation process for fractioningwhey. The whey feed is first flowed through a cream separator 61 forremoval of fat and lipids therefrom. The cream separator 61 may comprisea polymeric or cellulosic filtration membrane that has a retentatemolecular weight within a range of from about 200,000 to about 3,000,000MW, or a bubble point range of from about 65 to about 120 psig. Apreferred filtration membrane for separating fat and liquids is apolymeric membrane having a bubble point of about 80 psig. Commerciallyavailable membranes such as BTS 80 manufactured by U.S. Filters (SanDiego, Calif.) or RC 100 manufactured by Nadir Filtration GmbH(Wiesbaden, Germany) are most preferred.

[0278] Subsequently, the fat free whey from cream separator 61 is flowedthrough a cross-flow filtration module 62 to form a retentate mixturethat includes β-lactoglobulin, bovine serum albumin (BSA), and IgG.Filtration membranes used in filtration module 62 are characterized by aretentate molecular weight in a range of about 20,000 to about 40,000MW, and preferably are cellulosic membranes having a retentate molecularweight characteristic of about 30,000 MW.

[0279] Permeate from filtration module 62 then can be flowed throughfiltration module 63 for retention of α-lactalbumin andglycomacropeptide (GMP), while filtration module 63 can comprisepolymeric or cellulosic filtration membrane having a retentate molecularweight of about 1,000 to about 20,000 MW. The membrane of choice is acellulosic membrane of retentate molecular weight of about 5,000 MW.

[0280] Subsequently, permeate from filtration module 63 can be used toproduce sialyllactose and lactose-rich fractions, by sequentiallypassing such permeate through filtration modules 64 and 65.

[0281]FIG. 7 illustrates yet another embodiment of the presentinvention, relating to a process for fractioning whey into fat andlipids, whey protein isolates (WPI), lactose, and water, usingsequentially arranged filtration modules 71, 72, 73, and 74. Watergenerated by the last filtration module 74 can be recycled for cleaningand purging upstream filtration modules 72 and 73.

[0282] FIGS. 8-14 depict various embodiments of the present inventionfor separation of nutritional component from milk, or skim milk whey,using various filtration membranes.

[0283] The following table summarizes the characteristics of suitablemembranes for specifically separating one or more milk components: TABLE1 CHOICE OF MEMBRANES Membrane Description Isolates/Retentate (General)Preferred Membrane Milk Concentrate Polymeric or Cellulosic Polymericand 5,000-20,000 5,000-40,000 MW MW 5,000 MW Milk Concentrate withPolymeric or Cellulosic Polymeric and 80 to 100 PSIG Standarized ProteinContent 200,000-3,000,000 MW (BTS* 80 or BTS* 100) bubble point 65-120psig Cellulosic 1,000,000 MW Bacteria Pore size 0.1-10 micronsCellulosic, Ceramic and Polymeric Fat and Lipids Polymeric or CellulosicPolymeric and 80 psig 200,000-3,000,000 MW (BTS* 80 or RC** 100) bubblepoint 65-120 psig Casein 100,000-3,000,000 MW Polymeric and 80-100 psigbubble point 65-120 psig (BTS* 100) WPI Polymeric Cellulosic and 5,000MW 5,000-40,000 MW (RC** 5) 5,000-20,000 MW 5,000-10,000 MWSialyllactose Enriched WPI Polymeric (PES*** 5) 5,000-10,000 MW IgG &Albumin Polymeric or Cellulosic (RC** 100) 50,000-300,000 MWBeta-lactoglobulin Cellulosic (RC** 30) 10,000-50,000 MWAlpha-lactoglobulin depleted Cellulosic (RC** 30) WPI 20,000-40,000 MWBeta-lactoglobulin, IgG, and Cellulosic Cellulosic and 30,000 MW Albumin20,000-40,000 MW Alpha-lactoglobulin Polymeric or Cellulosic Cellulosicand 5,000 MW 1,000-20,000 MW (RC** 5) Sialyllactose or other complexPolymeric Polymeric + 1,000-3,500 MW carbohydrates 500-10,000 MWPolymeric + 1,000-3,000 MW 800-5,000 MW (PES**** 2 kD) Lactose ReverseOsmosis Rejecting 98% of the lactose Polymeric + Cellulosic Rejecting >=80% NaCl Lactoferrin Cellulosic 30,000-100,000 MW

[0284] TABLE 2 Clarification of Whey¹ No Diafiltration Whey Feed BTS80Permeate Retentive Composition Composition Yield Fat and Lipids 0.05%0.02% Protein 0.89% 0.71% 79.8% Non-protein Nitrogen 0.18% 0.14% WheyProtein Nitrogen 0.65 mg N/g 0.77 mg N/g Undenatured Whey Protein 58.4%86.18%  GMP 0.95 mg/ml 0.83 mg/ml 87.4% α-Lactalbumin 0.10% 0.08%   80%β-Lactoglobulin 0.35% 0.29% 82.8% IgG <0.05%  <0.05%  Bovine SerumAlbumin <0.05%  <0.05%  Galactose, Enzymatic 0.02% 0.01% Lactose,Enzymatic 4.64% 4.58% 98.7% Flow Velocity 40 LM²H

[0285] TABLE 3 Concentration of Whey 10X with 7X Diafiltration by TwoMembranes BTS80 PES5 Concen- RC5 Concen- Permeate trate of BTS80 trateof BTS80 Composition Permeate Permeate Fat and Lipids 0.02% 0.06% 0.01%Protein 0.71% 7.33% 7.47% Non-protein Nitrogen 0.14% 0.36% 0.23% WheyProtein Nitrogen 0.77 mg N/g 11.08 mg N/g 11.24 mg N/g Undenatured Whey86.18%   100% 99.04%  Protein GMP 0.83 mg/ml 7.3 mg/ml 7.0 mg/mlα-Lactalbumin 0.08%  1.1%  1.1% β-Lactoglobulin 0.29%  4.1%  4.5% IgG<0.05%  0.38% 0.42% Bovine Serum <0.05%  0.22% 0.24% Albumin Galactose,Enzymatic 0.01% <0.01%  <0.01%  Lactose, Enzymatic 4.58% <0.01%  0.05%Flow Velocity 40 LM²H 35 LM²H 32 LM²H

[0286] TABLE 4 WPI Membrane PES5 Concentrate and PES5 Permeate Pool(prior to diafiltration) BTS80 Permeate PES5 Concentrate PES5 Permeateof Retentate Composition of BTS80 Permeate BTS80 Permeate Yield Fat,Base Hydrolysis 0.02% 0.06% 0.02% Protein 0.71% 7.33% 0.18% Non-proteinNitrogen 0.14% 0.36% 0.15% Whey Protein Nitrogen 0.77 mg N/g 11.08 mgN/g <0.01 mg N/g Undenatured Whey Protein 58.4%  100% Zero GMP 0.83mg/ml 7.3 mg/ml <0.3 mg/ml 87.9% α-Lactalbumin 0.08%  1.1% <0.05%   100%β-Lactoglobulin 0.29%  4.1% <0.05%   100% IgG <0.05%  0.38% <0.05% Bovine Serum Albumin <0.05%  0.22% <0.05%  Galactose, Enzymatic 0.01%<0.01%  0.01% Lactose, Enzymatic 4.58% <0.01%  4.62% No Lactose FlowVelocity 40 LM²H 35 LM²H

[0287] TABLE 5 WPI Membrane RC5 Concentrate and RC5 Permeate Pool (priorto diafiltration) BTS80 Permeate RC5 Concentrate RC5 Permeate ofRetentate Composition of BTS80 Permeate BTS80 Permeate Yield Fat, BaseHydrolysis 0.02% 0.01% 0.02% Protein 0.71% 7.47% 0.18% Non-proteinNitrogen 0.14% 0.23% 0.10% Whey Protein Nitrogen 0.77 mg N/g 11.24 mgN/g <0.01 mg N/g Undenatured Whey 58.4% 99.04%  Zero Protein GMP 0.83mg/ml 7.0 mg/ml <0.3 mg/ml 84.3% α-Lactalbumin 0.08%  1.1% <0.05%   100%β-Lactoglobulin 0.29%  4.5% <0.05%   100% IgG <0.05%  0.42% <0.05% Bovine Serum <0.05%  0.24% <0.05%  Albumin Galactose, Enzymatic 0.01%<0.01%  0.01% Lactose, Enzymatic 4.58% 0.05% 4.25% 0.05% Flow Velocity40 LM²H 32 LM²H

[0288] TABLE 6 10X concentration and 10X Diafiltration of StartingMaterial RC30 Concentrate of PES5 Concentrate of BTS80 Permeate BTS80Permeate RC30 Permeate Retentive Composition (β-Lactoglobulin Fraction)(α-Lactalbumin Fraction) Yields Fat, Base Hydrolysis 0.02% <0.01% <0.01%  Protein (Kjeldahl) 0.71% 4.45% 1.56% Non-protein Nitrogen 0.14%0.09% 0.13% Whey Protein Nitrogen 0.77 mg N/g 6.76 mg N/g 2.03 mg N/gUndenatured Whey 58.4% 98.9% 90.5% Protein GMP 0.83 mg/ml 3.1 mg/ml 2.7mg/ml α-Lactalbumin 0.08% 0.15% 0.53% 66.2% (84.1% Purity)β-Lactoglobulin 0.29%  3.5% 0.08%  100% (82.9% Purity) IgG <0.05%  0.32%<0.05% Bovine Serum <0.05%  0.20% <0.05% Albumin Galactose, Enzymatic0.01% <0.01%  <0.01% Lactose, Enzymatic 4.58% <0.01%  <0.01% No LactoseFlow Velocity 40 LM²H 32 LM²H 45 LM²H

[0289] While the invention has been described herein with respect tovarious illustrative aspects, features and embodiments thereof, it willbe recognized that the invention is not thus limited, but that thepresent invention extends to and encompasses other features,modifications, and alternative embodiments, as will readily suggestthemselves to those of ordinary skill in the art based on the disclosureand illustrative teachings herein. The claims that follow are thereforeto be construed and interpreted as including all such features,modifications and alternative embodiments, within their spirit andscope.

What is claimed is:
 1. A method for sequentially separating componentsof milk, comprising the steps of: (a) providing a milk source; (b)effectuating a sufficient flow of milk from the milk source through oneor more cross-flow filtration modules, using one or more fluid deliverymeans, wherein each fluid delivery means is connected to at least onecross-flow filtration module; and (c) sequentially capturing one or morefiltration fractions generated by the cross-flow filtration modules. 2.A method according to claim 1, wherein each cross-flow filtration modulecomprises at least one permeate, at least one inlet, at least oneoutlet, and multiple fluid-flow sub-channels each extending between theinlet and outlet, that are of equal length to one another as measuredbetween the inlet and the outlet.
 3. A method according to claim 1,wherein the cross-flow filtration modules comprise filtration membranesselected from the group consisting of cellulose-based membranes,polymer-based membranes, and ceramic-based membranes.
 4. A methodaccording to claim 1, wherein the milk from the milk source is flownthrough a cream separator upstream of the cross-flow filtration modulesto remove at least part of a fatty component of the milk.
 5. A methodaccording to claim 1, wherein the milk is pasteurized before beingflowed to the cross-flow filtration modules.
 6. A method according toclaim 1, further comprising the step of controlling and monitoringtemperature of the fluid within the cross-flow filtration modules.
 7. Amethod according to claim 1, further comprising the step of recyclingwater generated by the cross-flow filtration modules.
 8. A methodaccording to claim 1, wherein the milk is flowed through a cross-flowfiltration module to be separated into a casein-rich fraction and acasein-depleted fraction.
 9. A method according to claim 8, wherein thecasein-rich fraction of the milk is captured as retentate of thecross-flow filtration module, and wherein the casein-depleted fractionof the milk is captured as permeate of the cross-flow filtration module.10. A method according to claim 8, wherein the cross-flow filtrationmodule comprises a cellulose-based membrane selected from the groupconsisting of cellulose membranes, cellulose acetate membranes, andregenerated cellulose membranes.
 11. A method according to claim 8,wherein the cross-flow filtration module comprises a membrane having anaverage pore size in a range of from about 100 KD to about 3000 KD. 12.A method according to claim 8, wherein the cross-flow filtration modulecomprises a membrane having an average pore size in a range of fromabout 100 KD to about 1000 KD.
 13. A method according to claim 8,wherein the cross-flow filtration module comprises a membrane having anaverage pore size in a range of from about 100 KD to about 500 KD.
 14. Amethod according to claim 8, wherein the cross-flow filtration modulecomprises a regenerated cellulose membrane having an average pore sizeof about 100 KD.
 15. A method according to claim 8, further comprisingthe step of concentrating and/or diafiltering the casein-rich fraction.16. A method according to claim 8, further comprising the step ofconcentrating and/or diafiltering the casein-depleted fraction.
 17. Amethod according to claim 8, wherein the casein-rich fraction is used tomanufacture a diary product selected from the group consisting of:cheese, milk powder, and substrate for milk protein concentrate.
 18. Amethod according to claim 8, wherein the casein-depleted fraction isused to manufacture a diary product selected from the group consistingof: whey protein isolates, whey protein subcomponents, and whey proteinconcentrates.
 19. A method according to claim 8, further comprising thesteps of: adding fatty component of milk to the casein-rich fraction;and drying said casein-rich fraction to form milk powder enriched withthe fatty component of milk.
 20. A method according to claim 1,comprising the steps of: optionally flowing the milk from the milksource through a first cross-flow filtration module to remove at least aportion of bacteria contained therein; flowing the milk, optionallyfiltered in the first cross-flow filtration module, through a secondcross-flow filtration module to separate the milk into a casein-richfraction and a casein-depleted fraction; capturing the casein-richfraction; flowing the casein-depleted fraction of the milk through athird cross-flow filtration module to form a fraction that is enrichedwith albumin and immunoglobulins and a fraction that is depleted ofalbumin and immunoglobulins; capturing the fraction that is enrichedwith albumin and immunoglobulins; flowing the fraction that is depletedof albumin and immunoglobulins of the milk through a fourth cross-flowfiltration module to form a β-lactoglobulin-rich fraction and aβ-lactoglobulin-depleted fraction; capturing the β-lactoglobulin-richfraction; flowing the β-lactoglobulin-depleted fraction of the milkthrough a fifth cross-flow filtration module to form aα-lactalbumin-rich fraction and a α-lactalbumin-depleted fraction;capturing the α-lactalbumin-rich fraction; flowing theα-lactalbumin-depleted fraction of the milk through a sixth cross-flowfiltration module to form a complex carbohydrates rich fraction and acomplex carbohydrates depleted fraction; capturing the complexcarbohydrates rich fraction; flowing the complex carbohydrates depletedfraction through a seventh cross-flow filtration module to form alactose-rich fraction and a lactose-depleted fraction; capturing thelactose-rich fraction; and discharging and/or recyclying thelactose-depleted fraction of milk.
 21. A method according to claim 20,further comprising the step of pasteurizing the milk source and/or anyfraction of the milk components generated therein.
 22. A methodaccording to claim 20, wherein the cross-flow filtration modulescomprise filtration membranes selected from the group consisting ofcellulose-based membranes, polymer-based membranes, and ceramic-basedmembranes.
 23. A method according to claim 20, wherein the secondcross-flow filtration module comprises a cellulose-based membraneselected from the group consisting of cellulose membranes, celluloseacetate membranes, and regenerated cellulose membranes.
 24. A methodaccording to claim 20, wherein the second cross-flow filtration modulecomprises a membrane having average pore size in the range from about100 KD to about 3000 KD.
 25. A method according to claim 20, wherein thesecond cross-flow filtration module comprises a membrane having anaverage pore size in a range of from about 100 KD to about 1000 KD,selected from the group consisting of cellulose-based membranes selectedfrom the group consisting of cellulose membranes, cellulose acetatemembranes, and regenerated cellulose membranes.
 26. A method accordingto claim 20, wherein the second cross-flow filtration module comprises apolymeric membrane having an average pore size in a range of between 800KD and 2500 KD and/or a measured bubble point between 65 and 120 PSIG.27. A method according to claim 20, wherein the second cross-flowfiltration module comprises a regenerated cellulose membrane having anaverage pore size of about 100 KD.
 28. A method according to claim 20,further comprising the step of separating and purifying albumin andimmunoglobulins from the fraction that is enriched with albumin andimmunoglobulins, using a method selected from the group consisting ofchromatography, cross-flow filtration, cross-flow chromatography, anddiafiltration.
 29. A method according to claim 20, further comprisingthe step of separating and purifying β-lactoglobulin from theβ-lactoglobulin-rich fraction of the milk, using a method selected fromthe group consisting of chromatography, cross-flow filtration,cross-flow chromatography, and diafiltration.
 30. A method according toclaim 20, further comprising the step of separating and purifyingα-lactalbumin from the α-lactalbumin-rich fraction of the milk, using amethod selected from the group consisting of chromatography, cross-flowfiltration, cross-flow chromatography, and diafiltration.
 31. A methodaccording to claim 30, further comprising the step of adding theseparated and purified α-lactalbumin into the casein-depleted fractionof the milk generated by the second cross-flow filtration module to forman α-lactalbumin-enriched soluble milk protein concentrate.
 32. A methodaccording to claim 31, further comprising the step of drying theα-lactalbumin-enriched soluble milk protein concentrate to form a powderproduct.
 33. A method according to claim 20, further comprising the stepof separating and purifying complex carbohydrates from the complexcarbohydrates-rich fraction of the milk, using a method selected fromthe group consisting of chromatography, cross-flow filtration,cross-flow chromatography, and diafiltration.
 34. A method according to33, further comprising the step of fractioning the complex carbohydratesinto one or more subcomponents using one or more cross-flow filtrationmodules.
 35. A method according to claim 20, further comprising the stepof subjecting the lactose-rich fraction of the milk to a bacterialprocess and/or an enzymatic process.
 36. A method according to claim 20,further comprising the step of fermenting the lactose-rich fraction ofthe milk to produce at least one product selected from the groupconsisting of lactobacillus, lactic acid, and Vitamin B-12.
 37. A methodaccording to claim 20, further comprising the step of crystallizing thelactose-rich fraction of the milk to produce at least one productselected from the group consisting of lactobacillus, lactic acid, andVitamin B-12.
 38. A method according to claim 20, further comprising thestep of combining the casein-rich fraction from the second cross-flowfiltration module with the α-lactalbumin-rich fraction from the fifthcross-flow filtration module to form an α-lactalbumin-enriched substratefor cheese manufacturing.
 39. A method according to claim 20, furthercomprising the step of drying at least one of the captured fractions ofmilk by a method selected from the group consisting of lyophilization,spray-drying, freeze-drying, crystallization, and evaporation.
 40. Amethod according to claim 20, wherein each cross-flow filtration moduleis connected to at least one fluid delivery means for flowing the milkor a fraction of the milk therethrough.
 41. A method according to claim20, wherein temperature of each cross-flow filtration module iscontrolled and monitored by temperature controlling/monitoring means.42. A method according to claim 1, wherein sialyllactose is isolatedfrom the milk, said method comprising the steps of: optionally flowingthe milk from the milk source through a first cross-flow filtrationmodule to filter out at least a portion of bacteria contained therein;flowing the milk, optionally filtered in the first cross-flow filtrationmodule, through a second cross-flow filtration module to separate themilk into a casein-rich fraction and a casein-depleted fraction;capturing the casein-rich fraction; flowing the casein-depleted fractionof the milk through a third cross-flow filtration module to form afraction that is enriched with milk proteins selected from the groupconsisting of albumin, immunoglobulins, β-lactoglobulin, andα-lactalbumin, and a fraction that is depleted of said milk proteins;capturing the fraction that is enriched with milk proteins selected fromthe group consisting of albumin, immunoglobulins, β-lactoglobulin, andα-lactalbumin; flowing the fraction that is depleted of said milkproteins through a fourth cross-flow filtration module to form asialyllactose-enriched fraction and a sialyllactose-depleted fraction;capturing the sialyllactose-enriched fraction; and discharging thesialyllactose-depleted fraction.
 43. A method according to claim 1,wherein the milk source supplies casein-depleted whey, and whereinsialyllactose is separated from said casein-depleted whey, comprisingthe steps of: optionally flowing the casein-depleted whey from the milksource through a first cross-flow filtration module to filter out atleast a portion of bacteria contained therein; flowing thecasein-depleted whey, optionally filtered in the first cross-flowfiltration module, through a second cross-flow filtration module to forma fraction that is enriched with milk proteins selected from the groupconsisting of albumin, immunoglobulins, β-lactoglobulin, andα-lactalbumin, and a fraction that is depleted of said milk proteins;capturing the fraction that is enriched with milk proteins selected fromthe group consisting of albumin, immunoglobulins, β-lactoglobulin, andα-lactalbumin; flowing the fraction that is depleted of said milkproteins through a third cross-flow filtration module to form asialyllactose-enriched fraction and a sialyllactose-depleted fraction;capturing the sialyllactose-enriched fraction; and discharging thesialyllactose-depleted fraction.
 44. A method according to claim 1,wherein immunoglobulins are isolated and purified from the milk, saidmethod comprising the steps of: optionally flowing the milk from themilk source through a first cross-flow filtration module to filter outat least a portion of bacteria contained therein; flowing the milk,optionally filtered in the first cross-flow filtration module, through asecond cross-flow filtration module to separate the milk into acasein-rich fraction and a casein-depleted fraction; capturing thecasein-rich fraction; flowing the casein-depleted fraction of the milkthrough a third cross-flow filtration module to form animmunoglobulin-rich fraction and an immunoglobulin-depleted fraction;and capturing both the immunoglobulin-rich fraction and theimmunoglobulin-depleted fraction.
 45. A method according to claim 44further comprising the additional step of concentrating and/ordiafiltering the immunoglobulin-rich fraction.
 46. A method according toany one of claims 44 and 45 further comprising the additional step ofpurifying immunoglobulins from the immunoglobulin-rich fraction by amethod selected from the group consisting of chromatography, cross-flowfiltration, cross-flow chromatography, and diafiltration.
 47. A methodaccording to any one of claims 44, 45 and 46 further comprising theadditional step of concentrating and/or diafiltering the immunoglobulindepleted fraction for further uses.
 48. A method according to any one ofclaims 44, 45, 46 and 47 wherein the immunoglobulins have therapeuticeffects.
 49. A method according to any one of claims 44, 45, 46 and 47wherein the immunoglobulins are used to treat gastrointestinal trackdisorder.
 50. A method according to any one of claims 44, 45, 46 and 47wherein the immunoglobulins are used to treat a mammal of the samespecies as that of the milk source.
 51. A method according to any one ofclaims 44, 45, 46 and 47 wherein the immunoglobulins are used to treat amammal of a different species from that of the milk source.
 52. A methodaccording to claim 1, wherein the milk source supplies fluid containingmixtures of complex carbohydrates and lactose, and wherein complexcarbohydrates are isolated and purified from said mixtures, said methodcomprising the steps of: flowing the fluid mixtures from the milk sourcethrough a first cross-flow filtration module to separate said mixturesinto a complex carbohydrates rich fraction and a complex carbohydratedepleted fraction; capturing both the complex carbohydrates richfraction and the complex carbohydrates depleted fraction; concentratingand/or diafiltering the complex carbohydrates rich fraction to obtaincomplex carbohydrates; crystalizing and/or drying the complexcarbohydrates; and concentrating and/or diafiltering the complexcarbohydrates depleted fraction to obtain lactose; and crystalizingand/or drying the lactose.
 52. A method according to claim 1, whereinsialyllactose is isolated from the milk, said method comprising thesteps of: flowing the milk from the milk source through a firstcross-flow filtration module to separate the milk into a casein-richfraction and a casein-depleted fraction; capturing the casein-richfraction; flowing the casein-depleted fraction of the milk through asecond cross-flow filtration module to form a fraction that is enrichedwith milk proteins selected from the group consisting of albumin,immunoglobulins, β-lactoglobulin, and α-lactalbumin, and a fraction thatis depleted of said milk proteins; capturing the fraction that isenriched with milk proteins selected from the group consisting ofalbumin, immunoglobulins, β-lactoglobulin, and α-lactalbumin; flowingthe fraction that is depleted of said milk proteins through a thirdcross-flow filtration module to form a sialyllactose-enriched fractionand a sialyllactose-depleted fraction; capturing thesialyllactose-enriched fraction; and discharging thesialyllactose-depleted fraction.
 52. A method according to claim 1,wherein the milk source directly supplies casein-depleted whey, andwherein sialyllactose is separated from said casein-depleted whey,comprising the steps of: flowing the casein-depleted whey from the milksource through a first cross-flow filtration module to form a fractionthat is enriched with milk proteins selected from the group consistingof albumin, immunoglobulins, β-lactoglobulin, and α-lactalbumin, and afraction that is depleted of said milk proteins; capturing the fractionthat is enriched with milk proteins selected from the group consistingof albumin, immunoglobulins, β-lactoglobulin, and α-lactalbumin; flowingthe fraction that is depleted of said milk proteins through a secondcross-flow filtration module to form a sialyllactose-enriched fractionand a sialyllactose-depleted fraction; capturing thesialyllactose-enriched fraction; and discharging thesialyllactose-depleted fraction.
 53. A method according to claim 1,wherein immunoglobulins are isolated and purified from the milk, saidmethod comprising the steps of: flowing the milk from the milk sourcethrough a first cross-flow filtration module to separate the milk into acasein-rich fraction and a casein-depleted fraction; capturing thecasein-rich fraction; flowing the casein-depleted fraction of the milkthrough a second cross-flow filtration module to form animmunoglobulin-rich fraction and an immunoglobulin-depleted fraction;capturing both the immunoglobulin-rich fraction and theimmunoglobulin-depleted fraction;
 54. A method according to claim 53further comprising the additional step of concentrating and/ordiafiltering the immunoglobulin-rich fraction.
 55. A method according toany one of claims 53 and 54 further comprising the additional step ofpurifying immunoglobulins from the immunoglobulin-rich fraction by amethod selected from the group consisting of chromatography, cross-flowfiltration, cross-flow chromatography, and diafiltration.
 56. A methodaccording to claim 53 further comprising the additional step ofconcentrating and/or diafiltering the immunoglobulin depleted fractionfor further uses.
 57. An apparatus for sequentially separatingcomponents of milk, comprising: (a) a milk source; (b) one or morecross-flow filtration modules communicatively connected to said milksource, for generating one or more filtration fractions; (c) one or morefluid delivery means connected to each of said cross-flow filtrationmodules to effectuate flow of milk through said cross-flow filtrationmodules for separation of milk components; and (d) one or more meansdownstream of each of said cross-flow filtration modules forsequentially capturing one or more filtration fractions generated by thecross-flow filtration modules.
 58. An apparatus according to claim 50,wherein each cross-flow filtration module comprises at least onepermeate, at least one inlet, at least one outlet, and multiplefluid-flow sub-channels that are of equal length between the inlet andthe outlet.
 59. An apparatus according to claim 57, wherein the one ormore cross-flow filtration modules comprise a filtration membraneselected from the group consisting of cellulose-based membranes,polymer-based membranes, and ceramic-based membranes.
 60. An apparatusaccording to claim 57, further comprising a cream separator upstream ofsaid cross-flow filtration modules for removing at least a portion offatty component from the milk.
 61. An apparatus according to claim 57,further comprising a pasteurizer upstream and/or downstream of said oneor more cross-flow filtration modules for pasteurizing the milk.
 62. Anapparatus according to claim 57, further comprising temperaturecontrolling/monitoring means for controlling and monitoring temperatureof said milk and/or filtration fractions generated by the one or morecross-flow filtration modules.
 63. An apparatus according to claim 57,comprising a cross-flow filtration module for separating the milk fromthe milk source into a casein-rich fraction and a casein-depletedfraction.
 64. An apparatus according to claim 63, wherein the cross-flowfiltration module comprises membranes selected from the group consistingof cellulose-based membranes, polymer-based membranes, and ceramic-basedmembranes.
 65. An apparatus according to claim 63, wherein thecross-flow filtration module comprises a membrane having an average poresize in a range of from about 100 KD to about 3000 KD.
 66. An apparatusaccording to claim 63, wherein the cross-flow filtration modulecomprises a membrane having an average pore size in a range of fromabout 100 KD to about 1000 KD, selected from the group consisting ofcellulose-based membranes selected from the group consisting ofcellulose membranes, cellulose acetate membranes, and regeneratedcellulose membranes.
 67. An apparatus according to claim 63, wherein thecross-flow filtration module comprises a polymeric membrane having anaverage pore size between 800 KD and 2500 KD and/or a measured bubblepoint between 65 and 120 PSIG.
 68. A method according to claim 63,wherein the cross-flow filtration module comprises a regeneratedcellulose membrane having an average pore size of about 100 KD
 69. Anapparatus according to claim 57, comprising: an optional firstcross-flow filtration module downstream of the milk source andcommunicatively connected thereto for filtering out all or at least aportion of bacteria contained in the milk; a second cross-flowfiltration module, downstream of the first cross-flow filtration moduleif provided and communicatively connected thereto, or if not provided,then communicatively connected directly to the milk source, whichseparates the milk into a casein-rich fraction and a casein-depletedfraction; means connected to said second cross-flow filtration modulefor capturing the casein-rich fraction; a third cross-flow filtrationmodule downstream of the second cross-flow filtration module andcommunicatively connected thereto, which receives the casein-depletedfraction and further separates it into a fraction that is enriched withalbumin and immunoglobulins and a fraction that is depleted of albuminand immunoglobulins; means connected to said third cross-flow filtrationmodule for capturing the fraction that is enriched with albumin andimmunoglobulins; a fourth cross-flow filtration module downstream of thethird cross-flow filtration module and communicatively connectedthereto, which receives the fraction that is depleted of albumin andimmunoglobulins and further separates it into a β-lactoglobulin-richfraction and a β-lactoglobulin-depleted fraction; means connected tosaid fourth cross-flow filtration module for capturing theβ-lactoglobulin-rich fraction; a fifth cross-flow filtration moduledownstream of the fourth cross-flow filtration module andcommunicatively connected thereto, which receives theβ-lactoglobulin-depleted fraction and further separates it into aα-lactalbumin-rich fraction and a α-lactalbumin-depleted fraction; meansconnected to said fifth cross-flow filtration module for capturing theα-lactalbumin-rich fraction; a sixth cross-flow filtration moduledownstream of the fifth cross-flow filtration module and communicativelyconnected thereto, which receives the α-lactalbumin-depleted fractionand further separates it into a complex carbohydrates rich fraction anda complex carbohydrates depleted fraction; means connected to said sixthcross-flow filtration module for capturing the complex carbohydratesrich fraction; a seventh cross-flow filtration module downstream of thesixth cross-flow filtration module and communicatively connectedthereto, which receives the complex carbohydrates depleted fraction andfurther separates it into a lactose-rich fraction and a lactose-depletedfraction; and means connected to said seventh cross-flow filtrationmodule for capturing the lactose-rich fraction; means for dischargingand/or recycling the lactose-depleted fraction.
 70. An apparatusaccording to claim 57, comprising: a first cross-flow filtration moduledownstream of the milk source and communicatively connected thereto,which separates the milk into a casein-rich fraction and acasein-depleted fraction; means connected to said first cross-flowfiltration module for capturing the casein-rich fraction; a secondcross-flow filtration module downstream of the first cross-flowfiltration module and communicatively connected thereto, which receivesthe casein-depleted fraction and further separates it into a fractionthat is enriched with albumin and immunoglobulins and a fraction that isdepleted of albumin and immunoglobulins; means connected to said secondcross-flow filtration module for capturing the fraction that is enrichedwith albumin and immunoglobulins; a third cross-flow filtration moduledownstream of the second cross-flow filtration module andcommunicatively connected thereto, which receives the fraction that isdepleted of albumin and immunoglobulins and further separates it into aβ-lactoglobulin-rich fraction and a β-lactoglobulin-depleted fraction;means connected to said third cross-flow filtration module for capturingthe β-lactoglobulin-rich fraction; a fourth cross-flow filtration moduledownstream of the third cross-flow filtration module and communicativelyconnected thereto, which receives the β-lactoglobulin-depleted fractionand further separates it into a α-lactalbumin-rich fraction and aα-lactalbumin-depleted fraction; means connected to said fourthcross-flow filtration module for capturing the α-lactalbumin-richfraction; a fifth cross-flow filtration module downstream of the fourthcross-flow filtration module and communicatively connected thereto,which receives the α-lactalbumin-depleted fraction and further separatesit into a complex carbohydrates rich fraction and a complexcarbohydrates depleted fraction; means connected to said fifthcross-flow filtration module for capturing the complex carbohydratesrich fraction; a sixth cross-flow filtration module downstream of thefifth cross-flow filtration module and communicatively connectedthereto, which receives the complex carbohydrates depleted fraction andfurther separates it into a lactose-rich fraction and a lactose-depletedfraction; and means connected to said sixth cross-flow filtration modulefor capturing the lactose-rich fraction; means for discharging and/orrecycling the lactose-depleted fraction.
 71. An apparatus according toany one of claims 69 and 70, further comprising a pasteurizer upstreamand/or downstream of any of the cross-flow filtration modules forpasteurizing the milk source or any one or more filtration fractionsgenerated by the cross-flow filtration modules.
 72. An apparatusaccording to any one claims 69 and 70, comprising multiple fluiddelivery means arranged in a manner that each cross-flow filtrationmodule is connected to at least one fluid delivery means, said fluiddelivery means function to effectuate a flow of the milk or a fractionof the milk through each cross-flow filtration module.
 73. An apparatusaccording to any one of claims 69 and 70, further comprising temperaturecontrolling/monitoring means for controlling and monitoring temperatureof said milk and/or filtration fractions generated by the cross-flowfiltration modules.
 74. An apparatus according to any one of claims 69and 70, further comprising a cream separator upstream of said cross-flowfiltration modules for removing all or at least a portion of fattycomponent from the milk.
 75. A method of milk separation, comprisingseparating milk to recover at least one milk product therefrom, bycross-flow membrane filtration, wherein said method does not include anychromatography or precipitation steps.
 76. The method of claim 75,wherein the milk product comprises a material selected from the groupconsisting of fats, lipids, insoluble casein, immunoglobulins, albumin,beta-lactoglobulin, alpha-lactalbumin, complex carbohydrates,siallyllactose, simple carbohydrates, lactose.
 77. The method of claim75, wherein the cross-flow membrane filtration is carried out in across-flow filtration module including a filter with geometricallyregular subchannels geometrically corresponding to one another in a flowpassage for said filtration, wherein operating conditions and/or saidsubchannels have been optimized with respect to shear rate and/orpermeate diffusion.
 78. A α-lactalbumin-enriched soluble milk proteinconcentrate.
 79. A β-lactoglobulin and α-lactalbumin-enriched wheyprotein isolate.
 80. A sialyllactose-enriched whey protein isolate.